Methods for producing a mosaic decoration having a planar surface

ABSTRACT

The present invention provides a method for producing a mosaic with a generally planar surface including the steps of providing a base substrate having a first side and a second side, wherein the base substrate has a height, providing at least one additional substrate having a first side and a second side, wherein the additional substrate has a height, and wherein the additional substrate is in the shape of a portion of the mosaic that will contain a more detailed portion of the mosaic, affixing the second side of the additional substrate to the first side of the base substrate in an area of the mosaic that will contain a more detailed portion of the mosaic, affixing relatively thicker pieces of tesserae to the first side of the base substrate, and affixing relatively thinner pieces of tesserae to the first side of the at least one additional substrate.

[0001] This application is a Divisional application of prior pendingU.S. patent application Ser. No.: 09/912,980, filed Jul. 25, 2001, nowU.S. Pat. No.: ______. The entire disclosure of the prior application ishereby incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] This invention relates generally to mosaics, and morespecifically, to producing mosaic decorations having a planar surface.

[0004] 2. Description of Related Art

[0005] Generally, mosaics are decorative objects made from various sizepieces or fragments of a hard substance, such as, for example, terracotta, glass, marble, or stone, selected and fitted together to form adesired design or image. Mosaics are not only found as independentpieces of art, but are also used to decorate architecture, ornamentfurniture, enhance jewelry, and adorn pots, boxes, vases, and the like.

[0006] The various pieces of material that comprise the mosaics, knownas tesserae, are usually positioned on a supporting surface and held inplace by some type of mortar. Thus, mosaics typically form a cracked orbroken image because of the mortar lines that are created between thevarious pieces of the mosaic.

[0007] Typically, the amount of detail present in a particular piece ofmosaic art is a function of the size of each piece of the mosaic, ortesserae, in relation to the overall size of the mosaic. For example, ifthe mosaic is relatively large, rather large, thick fragments may beused to produce a design or image with a relatively high degree ofdetail. Conversely, if the mosaic is relatively small, small fragmentsof the mosaic material must be used so that a high level of detail ismaintained.

[0008] However, although mosaics with a high degree of detail aredesirable, the costs associated with using thick pieces of mosaictesserae and the intense amount of labor involved in producing a large,detailed mosaic make sizeable, detailed mosaics quite expensive.

SUMMARY OF THE INVENTION

[0009] Unfortunately, known methods for producing mosaics do not allow amosaic to be produced that has a high-perceived value by virtue of itssize and level of detail, but is cost effective to produce. Thus, thepresent invention provides methods for producing a detailed mosaichaving different size mosaic tesserae in different areas of the mosaic,while maintaining a planar top surface. Specifically, this inventionprovides a multi-level supporting surface or substrate such that ahighly detailed portion of a mosaic, being formed of generally smaller,thinner mosaic tesserae, and a less detailed portion of the mosaic,being formed of generally larger, thicker mosaic tesserae, can bothappear as though they are formed of large, thick mosaic tesserae.

[0010] In the various exemplary embodiments of the methods for producinga detailed mosaic with a planar surface according to this invention, theless detailed portions of the mosaic, comprised of the larger, thickermosaic tesserae, are formed atop a base portion (or a single layer) ofthe support substrate, while the more detailed portions of the mosaic,comprised of the smaller, thinner mosaic tesserae, are formed atop araised portion (or a second layer) of the support substrate.

[0011] In one exemplary embodiment of this invention, a detailed andlabor intensive central portion, or medallion, is first created. Thecentral medallion is then surrounded by larger, thicker pieces of mosaictesserae, which are generally larger, thicker, and less detailed, butcoordinate and accentuate the central design.

[0012] In various exemplary embodiments of this invention, the mosaictesserae are marble. However, it should be understood that the mosaictesserae may be, for example, terra cotta, glass, stone, or any othermaterial capable of being selected and fitted together to form a desireddesign or image.

[0013] In various exemplary embodiments, the central medallion is madeof approximately ⅛″ thick tesserae while the outer design is fabricatedfrom tesserae that are approximately ⅜″ thick. Because the thinnermosaic tesserae can be cut and shaped more easily and accurately, thematerial and labor costs associated with the creation of a detailedcentral medallion is reduced. The thicker outer portion of the mosaicreduces production time of the mosaic because fewer pieces make up eachsquare foot. Furthermore, the thicker portions of the mosaic addstrength to the mosaic and contribute to an overall appearance that theentire mosaic is formed of thick mosaic tesserae.

[0014] Accordingly, this invention provides a multi-level supportingsubstrate such that a highly detailed portion of a mosaic and a lessdetailed portion of the mosaic can both appear as though they are formedof large, thick mosaic tesserae.

[0015] This invention separately provides a mosaic wherein a highlydetailed portion of a mosaic is formed of smaller, thinner mosaictesserae, and a less detailed portion of the mosaic is formed of larger,thicker mosaic tesserae.

[0016] This invention separately provides methods for producing adetailed mosaic with a planar surface.

[0017] This invention separately provides methods for mounting sectionsof mosaic tesserae of different heights, or thicknesses, in a mannerthat allows the sections of mosaic tesserae to be flush on a top surfaceand appear to be the same height, or thickness.

[0018] This invention separately provides a mosaic wherein more detailedportions of the mosaic are formed atop raised portions of a supportsubstrate, while less detailed portions are formed atop a base portionof the support substrate.

[0019] These and other features and advantages of this invention aredescribed in or are apparent from the following detailed description ofthe exemplary embodiments, the accompanying drawings, and/or theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The exemplary embodiments of this invention will be described indetail, with reference to the following figures, wherein like referencenumerals refer to like parts throughout the several views, and wherein:

[0021]FIG. 1A is a plan view of a top side of a first exemplaryembodiment of a mosaic decoration constructed using known methods forproducing a planar surface;

[0022]FIG. 1B is a schematic cross-sectional view taken along line 1-1of the mosaic decoration of FIG. 1A;

[0023]FIG. 1C is a schematic cross-sectional view taken along line 2-2of the mosaic decoration of FIG. 1A;

[0024]FIG. 2A is a plan view of a top side of a second exemplaryembodiment of a mosaic decoration constructed using known methods forproducing a planar mosaic surface;

[0025]FIG. 2B is a schematic cross-sectional view taken along line 1-1of the mosaic decoration of FIG. 2A;

[0026]FIG. 2C is a schematic cross-sectional view taken along line 2-2of the mosaic decoration of FIG. 2A;

[0027]FIG. 3A is a plan view of a top side of a third exemplaryembodiment of a mosaic decoration constructed using known methods forproducing a planar mosaic surface;

[0028]FIG. 3B is a schematic cross-sectional view taken along line 1-1of the mosaic decoration of FIG. 3A;

[0029]FIG. 3C is a schematic cross-sectional view taken along line 2-2of the mosaic decoration of FIG. 3A;

[0030]FIG. 4A is a plan view of a top side of a first exemplaryembodiment of a mosaic decoration with a planar mosaic surfaceconstructed according to the methods of this invention;

[0031]FIG. 4B is a perspective view showing the substrates used as abase for the mosaic decoration of FIG. 4A;

[0032]FIG. 4C is a schematic cross-sectional view taken along line 1-1of the mosaic decoration of FIG. 4A;

[0033]FIG. 4D is a schematic cross-sectional view taken along line 2-2of the mosaic decoration of FIG. 4A;

[0034]FIG. 5A is a plan view of a top side of a second exemplaryembodiment of a mosaic decoration with a planar mosaic surfaceconstructed according to the methods of this invention;

[0035]FIG. 5B is a perspective view showing the substrates used as abase for the mosaic decoration of FIG. 5A;

[0036]FIG. 5C is a schematic cross-sectional view taken along line 1-1of the mosaic decoration of FIG. 5A;

[0037]FIG. 5D is a schematic cross-sectional view taken along line 2-2of the mosaic decoration of FIG. 5A; and

[0038]FIG. 6 is a perspective view showing the substrates useable as abase for a third exemplary embodiment of a mosaic decoration with aplanar mosaic surface constructed according to the methods of thisinvention.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

[0039] For simplicity and clarification, the design factors and layoutof the detailed mosaic having a planar surface according to thisinvention are explained with reference to an exemplary embodiment of amosaic decoration having a planar surface according to this invention.The basic explanation of the mosaic decoration having a planar surfaceis applicable for the understanding and design of the constituentcomponents employed in the mosaic decoration having a planar surface ofthis invention.

[0040] Furthermore, for simplicity and clarification, the variousexemplary embodiments of this invention will be described with referenceto a mosaic decoration having a detailed central medallion. However, itshould be appreciated that the terms “central medallion” and “medallion”are for a basic explanation and understanding of certain of theconstituent components of the mosaic of this invention. Therefore, theterms “central medallion” and “medallion” are not to be construed aslimiting this invention, but should be understood to represent portionsof a mosaic decoration that feature increased detail when compared withat least one other portion of the mosaic.

[0041] It should be further understood that although the “medallion”shown in the included drawing figures includes a specific floral design,the “medallion” shown in the included drawing figures is merelyexemplary. The “medallion” may comprise any one of an infinite numberand/or combination of images, designs, shapes, colors, or the like thatmay be appear in a mosaic form that features at least one area havingincreased detail when compared with at least one other area of themosaic. Likewise, although the mosaic decoration shown in the includeddrawing figures has a particular shape and design, the mosaic decorationshown is merely one of an infinite number of sizes and shapes that amosaic decoration may take.

[0042] Furthermore, the shape, relative size, and placement of the“medallion”, as well as the design of the remaining portion(s) of themosaic decoration in the included drawing figures is for a basicexplanation and understanding of certain of the constituent componentsof the mosaic decoration of this invention and is not to be construed aslimiting this invention.

[0043]FIGS. 1A, 1B, and 1C show a first exemplary embodiment of a mosaicdecoration 100 constructed using known methods for producing a planarmosaic surface. Specifically, FIG. 1A shows a plan view of a top side ofthe mosaic decoration 100 while FIGS. 1B and 1C show cross-sectionalviews taken along line 1-1 and line 2-2, respectively, of the mosaicdecoration 100 of FIG. 1A.

[0044] As shown in FIGS. 1A-C, the mosaic decoration 100 includes asubstrate layer 110, a mortar layer 120, and a tesserae layer 130. Amosaic design is formed in the tesserae layer 130 by first placing acertain amount of mortar 122 atop the substrate layer 110. In thismanner, a mortar layer 120 is formed atop the substrate layer 110.Numerous pieces of material, such as pieces of individual mosaictesserae 132, are then placed atop the mortar layer 120 to form adesired image or pattern. An additional amount of mortar 122 istypically placed between each mosaic tesserae 132 to ensure that eachmosaic tesserae 132 remains in place.

[0045] As shown in FIGS. 1A and 1C, the mosaic decoration 100 comprisesan outer portion 134 and a central medallion 136. The outer portion 134does not contain a significant amount of detail. However, as shown inFIG. 1A, the central medallion 136 contains a relatively detailed floraldesign.

[0046] In order to efficiently and cost effectively reproduce thedetailed floral design in the central medallion 136, known methodsdictate that each mosaic tesserae 132 must be relatively thin. Thus, inorder to produce a planar top surface of the tesserae layer 130 usingknown methods, the height, or thickness, of each mosaic tesserae 132must be approximately the same. However, when each piece of mosaictesserae 132 is relatively thin, the mosaic tesserae 132, especially themosaic tesserae 132 in the outer portion 134, are easily broken.

[0047]FIGS. 2A, 2B, and 2C show a second exemplary embodiment of amosaic decoration 200 constructed using known methods for producing aplanar mosaic surface. Specifically, FIG. 2A shows a plan view of a topside of the mosaic decoration 200 while FIGS. 2B and 2C showcross-sectional views taken along line 1-1 and line 2-2, respectively,of the mosaic decoration 200 of FIG. 2A.

[0048] As shown in FIGS. 2A-C, the mosaic decoration 200 includes asubstrate layer 210, a mortar layer 220, mortar 222, a tesserae layer230, individual mosaic tesserae 232, an outer portion 234, and a centralmedallion 236. These elements correspond to similarly numbered elementsdescribed above, with reference to FIGS. 1A-1C.

[0049] However, as shown in FIGS. 2A-2C, each of the individual mosaictesserae 232 is thicker than the mosaic tesserae 132 of FIGS. 1A-1C.Although the thicker mosaic tesserae 232 in the mosaic 200 are lesslikely to break, the thicker mosaic tesserae 232 are not as easilybroken or cut into small pieces. Therefore, much of the detail in thefloral design of the central medallion 136, as shown in FIGS. 1A-1C,cannot be efficiently reproduced in the central medallion 236.

[0050]FIGS. 3A, 3B, and 3C show a third exemplary embodiment of a mosaicdecoration 300 constructed using known methods for producing a planarmosaic surface. Specifically, FIG. 3A shows a plan view of a top side ofthe mosaic decoration 300 while FIGS. 3B and 3C show cross-sectionalviews taken along line 1-1 and line 2-2, respectively, of the mosaicdecoration 300 of FIG. 3A.

[0051] As shown in FIGS. 3A-C, the mosaic decoration 300 includes asubstrate layer 310, a mortar layer 320, mortar 322, a tesserae layer330, individual mosaic tesserae 332, an outer portion 334, and a centralmedallion 336. These elements correspond to similarly numbered elementsdescribed above, with reference to FIGS. 1A-1C and 2A-2C.

[0052] However, as shown in FIGS. 3A-3C, the individual mosaic tesserae332 are not of a uniform height. Mosaic tesserae 332 of differingheights are typically made to appear flush on a top surface of a mosaicby first, creating the tesserae layer 330 on a front facing sheet offabric, paper, or plastic. This is accomplished by temporarily adheringthe top surface of the mosaic tesserae 332 to the front facing sheet.Then, a thick layer of mortar 322 is applied to the top surface of thesubstrate layer 310 to form the mortar layer 320. Once the mortar 322has been applied, the bottom side of the tesserae layer 330, while stilladhered to the front facing, is pressed into the mortar layer 320 untilall of the mosaic tesserae 332 have made at least some contact with themortar layer 320.

[0053] A flat object is often used to press the tesserae layer 330 intothe mortar layer 320. Thus, although the mosaic tesserae 332 are ofdiffering heights, the thick mortar layer 320 fills in the gaps betweenthe substrate layer 310 and the tesserae layer 330 so that a relativelyplanar surface is achieved on the top of the mosaic decoration 300.

[0054] Although this method allows smaller, thinner pieces of mosaictesserae 332 to be used to form the tesserae layer 330 and much of thedetail in the floral design to be reproduced in the central medallion336, one of the disadvantages of this method is that, as the tesseraelayer 330 is pressed into the thick mortar layer 320, a fair amount ofmortar 322 flows between the mosaic tesserae 332 and adheres to thefront facing. Because the front facing is not removed until after themortar 322 has dried, this method requires that a large amount ofcleaning be done to remove the excess mortar 322 that accumulates on thetop surface of the mosaic decoration 300. Furthermore, when small, thinpieces of mosaic tesserae 332 are used, such as, for example, in thearea of the central medallion 336, this method is quite impractical andclumsy.

[0055]FIGS. 4A, 4B, 4C, and 4D show a first exemplary embodiment of amosaic decoration 400 with a planar surface constructed according to themethods of this invention. Specifically, FIG. 4A shows a plan view of atop side of the mosaic decoration 400, FIG. 4B shows a perspective viewof the substrates used as a base for the mosaic decoration of FIG. 4A,and FIGS. 4C and 4D show cross-sectional views taken along line 1-1 andline 2-2, respectively, of the mosaic decoration 400 of FIG. 4A.

[0056] As shown in FIGS. 4A-D, the mosaic decoration 400 includes a basesubstrate layer 410, a secondary substrate layer 412, a mortar layer420, and a tesserae layer 430. In various exemplary embodiments, thebase substrate layer 410 and the secondary substrate layer 412 arecomprised of a material with a coefficient of expansion substantiallysimilar to the coefficient of expansion of the materials that make upthe tesserae layer 430. In various exemplary embodiments, the basesubstrate layer 410 and the secondary substrate layer 412 are made ofBaltek®, which is produced by Baltek Corporation.

[0057] The mortar layer 420 is formed atop the base substrate layer 410and the secondary substrate layer 412 by placing a certain amount ofmortar 422, such as, for example an adhesive, cement, epoxy, acrylic,grout, or the like, atop the base substrate layer 410 and the secondarysubstrate layer 412.

[0058] The tesserae layer 430 is made of numerous pieces of mosaictesserae 432. In various exemplary embodiments, the pieces of mosaictesserae 432 are, for example, terra cotta, glass, marble, or stone. Itshould be appreciated that appropriate materials for the base substratelayer 410, the secondary substrate layer 412, the mortar layer 420, andthe tesserae layer 430 are selected based on the desired appearance ofthe mosaic decoration 400 as well as the conditions that are expected tooccur during use of the mosaic decoration 400.

[0059] As shown in FIGS. 4A and 4D, the mosaic decoration 400 includesboth an outer portion 434 and a central medallion 436. The outer portion434 does not contain a significant amount of detail and, therefore, canbe made of relatively large, thick pieces of mosaic tesserae 432.Because the outer portion 434 is constructed of relatively large, thickpieces of mosaic tesserae 432, the outer portion 434 is located in anarea of the mosaic decoration 400 that is supported by the basesubstrate layer 410 and not the secondary substrate layer 412. Invarious exemplary embodiments, the pieces of mosaic tesserae 432 thatmake up the outer portion 434 are approximately ⅜″ thick.

[0060] As further shown in FIG. 4A, the mosaic decoration also includesa central medallion 436. The central medallion 436 contains a relativelydetailed floral design and, therefore, must be made of relatively smallpieces of mosaic tesserae 432. Because the central medallion 436 isconstructed of relatively small pieces of mosaic tesserae 432, thecentral medallion 436 is located in an area of the mosaic decoration 400that is supported by both the base substrate layer 410 and the secondarysubstrate layer 412. In this manner, although the central medallion 436is made of relatively small pieces of mosaic tesserae 432, therelatively small pieces of mosaic tesserae 432 that make up the centralmedallion 436 appear to be of the same thickness as the mosaic tesserae432 that make up the outer portion 434, by virtue of their placementatop the secondary substrate layer 412. In various exemplaryembodiments, the pieces of mosaic tesserae 432 that make up the centralmedallion 436 are approximately ⅛″ thick.

[0061] It should be appreciated that, in order to produce a generallyplanar surface on the top side of the mosaic decoration 400, thesecondary substrate layer 412 has a height, or thickness, that isapproximately equal to the difference between the height, or thickness,of the pieces of mosaic tesserae 432 that make up the outer portion 434and the height, or thickness, of the pieces of mosaic tesserae 432 thatmake up the central medallion 436. Thus, for example, if the pieces ofmosaic tesserae 432 that make up the outer portion 434 have a thicknessof approximately ⅜″ and the pieces of mosaic tesserae 432 that make upthe central medallion 436 have a thickness of approximately ⅛″, thesecondary substrate layer 412 will have a thickness of approximately ¼″.

[0062] In order to produce the mosaic decoration 400 with a generallyplanar top surface, the base substrate layer 410 is first provided.Then, a bottom side of the secondary substrate layer 412, in the shapeof the central medallion 436, is affixed to the center of the basesubstrate layer 410 on a top side thereof. Next, a portion of the mortarlayer 420 is applied to a top side of the secondary substrate layer 412.

[0063] Once the portion of the mortar layer 420 has been applied to thetop side of the secondary substrate layer 412, the pieces of mosaictesserae 432 that make up the central medallion 436 are affixed to a topside of the mortar layer 420 on the secondary substrate layer 412. Invarious exemplary embodiments, an additional amount of mortar 422 isplaced between each mosaic tesserae 432 to ensure that each mosaictesserae 432 remains in the proper place. It should be appreciated thatthe additional amount of mortar 422 may comprise grout, unsanded grout,mortar, cement, epoxy, acrylic, or the like.

[0064] It should be understood that smaller, thinner pieces of mosaictesserae 432 are selected and fitted together to form the detailedfloral design that makes up the central medallion 436. It should beappreciated that since the pieces of mosaic tesserae 432 that make upthe central medallion 436 are relatively thin, the mosaic tesserae 432can be, for example, hand cut into small shapes to provide enhanceddetail to the design in the central medallion 436.

[0065] When the detailed floral design in the central medallion 436 iscompleted, a portion of the mortar layer 420 is applied to a top side ofthe base substrate layer 410 in the outer portion 434. Once theremaining portion of the mortar layer 420 has been applied, the piecesof mosaic tesserae 432 that make up the outer portion 434 are affixed toa top side of the mortar layer 420 on the base substrate layer 410. Invarious exemplary embodiments, an additional amount of mortar 422 isplaced between each mosaic tesserae 432 to ensure that each mosaictesserae 432 remains in the proper place. It should be understood thatlarger, thicker pieces of mosaic tesserae 432 are selected and fittedtogether to form the design that makes up the outer portion 434.

[0066] Because the smaller, thinner mosaic tesserae 432 are affixed atopthe secondary substrate layer 412 and the larger, thicker mosaictesserae 432 are affixed atop the base substrate layer 410, a generallyplanar surface is produced on the top side of the mosaic decoration 400.

[0067]FIGS. 5A, 5B, 5C, and 5D show a first exemplary embodiment of amosaic decoration 500 with a planar surface constructed according to themethods of this invention. Specifically, FIG. 5A shows a plan view of atop side of the mosaic decoration 500, FIG. 5B shows a perspective viewof the substrates used as a base for the mosaic decoration of FIG. 5A,and FIGS. 5C and 5D show cross-sectional views taken along line 1-1 andline 2-2, respectively, of the mosaic decoration 500 of FIG. 5A.

[0068] As shown in FIGS. 5A-D, the mosaic decoration 500 includes a basesubstrate layer 510, a secondary substrate layer 512, a mortar layer520, mortar 522, a tesserae layer 530, an outer portion 534, and acentral medallion 536. These elements correspond to similarly numberedelements described above, with reference to FIGS. 4A-4C.

[0069] However, as shown in FIGS. 5A-5D, the mosaic decoration 500 alsoincludes two additional substrate layers 514. The additional substratelayers 514 provide the same benefit as the secondary substrate layer512. However, the additional substrate layers 514 allow areas of greaterdetail to be included in various areas of the mosaic decoration 500 inaddition to the central medallion 536.

[0070]FIG. 6 shows a perspective view of an exemplary embodiment of amulti-level base substrate 600 useable as a base for a third exemplaryembodiment of a mosaic decoration with a planar mosaic surfaceconstructed according to the methods of this invention. The multi-levelbase substrate 600 includes a base substrate layer 610 and a secondarysubstrate layer 612. These elements correspond to similarly numberedelements described above, with reference to FIGS. 4A-4D and 5A-5D.

[0071] However, the multi-level base substrate 600 also includes asupplementary substrate layer 616. The supplementary substrate layer 616allows a mosaic decoration (not shown) to be formed atop the multi-levelbase substrate 600 with three levels of detail. Thus, the mosaicdecoration (not shown) may include a relatively undetailed portionaffixed atop an exposed portion of the base substrate layer 610, a moredetailed portion affixed atop an exposed portion of the secondarysubstrate layer 612, and a highly detailed portion affixed atop thesupplementary substrate layer 616.

[0072] It should be appreciated that the height, or thickness, of eachof the base substrate layer 610, the secondary substrate layer 612, andthe supplementary substrate layer 616 is a function of the differencebetween the thickness of the thickest pieces of mosaic tesserae used andthe thickness of the mosaic tesserae used atop the secondary substratelayer 612 and the supplementary substrate layer 616.

[0073] It should be understood that additional substrate levels may beadded to produce a mosaic with additional levels of detail. Furthermore,a supplementary substrate layer similar to the supplementary substratelayer 616 may be used in combination with the mosaic decoration 400, ofFIGS. 4A-4D or the mosaic decoration 500, of FIGS. 5A-5D.

[0074] It should also be appreciated that although the mosaic decorationof this invention have been depicted and described with reference to arelatively detailed floral design surrounded by a less detailed field,the design depicted in the drawing figures and described herein ismerely exemplary and does not limit this invention.

[0075] Likewise, it should also be appreciated that while the secondarysubstrate layer, the additional substrate layers, and the supplementarysubstrate layer have been described as being adhered or affixed to thebase substrate layer, any of the secondary substrate layer, theadditional substrate layers, and/or the supplementary substrate layermay be carved, formed, or molded as an integral part of the basesubstrate layer.

[0076] While this invention has been described in conjunction with theexemplary embodiments outlined above, it is evident that manyalternatives, modifications, and variations will be apparent to thoseskilled in the art. Accordingly, the exemplary embodiments of theinvention, as set forth above, are intended to be illustrative, notlimiting. Various changes may be made without departing from the spiritand scope of the invention.

What is claimed is:
 1. A method for producing a mosaic with a generallyplanar surface comprising the steps of: providing a base substratehaving a first side and a second side, wherein the base substrate has aheight; providing at least one additional substrate having a first sideand a second side, wherein the at least one additional substrate has aheight, and wherein the at least one additional substrate is in theshape of a portion of the mosaic that will contain a more detailedportion of the mosaic; affixing the second side of the at least oneadditional substrate to the first side of the base substrate in an areaof the mosaic that will contain a more detailed portion of the mosaic;affixing relatively thicker pieces of tesserae to the first side of thebase substrate; and affixing relatively thinner pieces of tesserae tothe first side of the at least one additional substrate.
 2. The methodof claim 1, wherein each of the relatively thinner pieces of tesseraehave a height of approximately ⅛ inch.
 3. The method of claim 1, whereineach of the relatively thicker pieces of tesserae have a height ofapproximately ⅜ inch.
 4. The method of claim 1, wherein each of therelatively thinner pieces of tesserae have a height of approximately ⅜inch, and wherein each of the relatively thicker pieces of tesserae havea height of approximately ¾ inch.
 5. The method of claim 1, wherein thetesserae comprises various size pieces of terra cotta, glass, marble, orstone.
 6. The method of claim 1, wherein the base substrate comprises amaterial with a coefficient of expansion substantially similar to thecoefficient of expansion of the tesserae.
 7. The method of claim 1,wherein the additional substrate comprises a material with a coefficientof expansion substantially similar to the coefficient of expansion ofthe tesserae.
 8. The method of claim 1, wherein the tesserae is affixedto the base substrate and the additional substrate via an adhesive. 9.The method of claim 1, wherein the tesserae is affixed to the basesubstrate and the additional substrate via a mortar.
 10. The method ofclaim 1, wherein the additional substrate is affixed to the basesubstrate via an adhesive.
 11. A method for producing a mosaic with agenerally planar surface comprising the steps of: providing a basesubstrate having a first side and a second side, wherein the basesubstrate has at least one elevated portion, wherein a top surface ofthe elevated portion has a generally planar surface, and wherein the atleast one elevated portion is in the shape of a portion of the mosaicthat will contain a more detailed portion of the mosaic; and affixingrelatively thicker pieces of tesserae to the first side of the basesubstrate; and affixing relatively thinner pieces of tesserae to the topsurface of the at least one elevated portion of the base substrate. 12.The method of claim 11, wherein each of the relatively thinner pieces oftesserae have a height of approximately ⅛ inch.
 13. The method of claim11, wherein each of the relatively thicker pieces of tesserae have aheight of approximately ⅜ inch.
 14. The method of claim 11, wherein eachof the relatively thinner pieces of tesserae have a height ofapproximately ⅜ inch, and wherein each of the relatively thicker piecesof tesserae have a height of approximately ¾ inch.
 15. The method ofclaim 11, wherein the tesserae comprises various size pieces of terracotta, glass, marble, or stone.
 16. The method of claim 11, wherein thebase substrate comprises a material with a coefficient of expansionsubstantially similar to the coefficient of expansion of the tesserae.